Embeddable mounting device

ABSTRACT

The joist support block basically includes a pair of generally rectangular metal members, three metal spacer members, two vertical metal walls or members and a horizontal metal wall or member. The two vertical metal walls or members and a horizontal metal wall or member form a U-shaped support member, which allows the structural support member or joist to be easily coupled to the joist support block.

This is a division of application Ser. No. 09/148,501, filed Sep. 4,1998 now U.S. Pat. No. 6,111,197.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to an embeddable mounting device, whichis mounted in a block wall. More specifically, the present inventionrelates to an embeddable mounting device, which is utilized topermanently install electrical devices, such as fixtures, lights,switches, receptacles, speakers, etc., or a structural support memberwithin a concrete block or masonry wall in a security facility, such asa jail, prison, juvenile detention center, psychiatric hospital, etc.

2. Background Information

Many buildings are currently being constructed of concrete blocks. Ithas been a common practice within the construction industry that allconcrete block walls have affixed electrical boxes that accommodate thefinal connections of emergency lights, intercom speakers, switches,receptacles, etc. Also it is often necessary to attach structuralsupport members such as joists to the concrete block walls.

Prior to the setting of the block walls, electric conduit is installedeither in the concrete floor slab or hung from the ceiling. One commonpractice in the construction industry, and employed by manyelectricians, is to bring or “stub up” the electric conduit a distanceof about six to twelve inches above the finished slab. The masonryblocks are then set on the slab and over the electric conduit. As theconcrete block walls increase in height, the electrician must addadditional lengths of the conduits. The electrical boxes are then linkedto the ends of the conduits when the wall reaches the specified heightto the electrical boxes. This means that the electricians must work inconcert with the masons to assure the proper location and height of theelectrical boxes and to eliminate any delay that might be experienced.After the masons have constructed the concrete wall, the electricianmust begin his work through the final connections. If the masons havenot broken a hole in the concrete block to expose the conduit, theelectrician must first locate the area in which the fixture is to beinstalled and must force entry into the block by breaking a hole orcutting a hole in the block. If the hole is formed in the correctlocation within the concrete block wall, the electrician will find theconduit and wires leading out of the conduit and install it. The nextstep for the electrician to conclude the final installation of theintercom speakers, the electrical receptacles or switches, he mustattach a faceplate to the electric box so that the hole in the block iscovered. The conventional method of installation creates a hole thatcannot be defined in size and often the hole created cannot be coveredby the electric fixture faceplate. The conventional method of installingthe conduit within the block often causes the conduit to be placed outof plumb. In that event, the electric box that is to receive thefaceplate inevitably is not plumb and the faceplate is often not level.As this often occurs, the added cost of having the masons return topatch the hole results in a delay to the progress of the job and anoverrun in cost.

This invention is especially useful in the detention industry. It is acommon practice within the detention industry for their new constructionprojects to construct the walls of a detection facility out of concreteblocks. Detention wall construction requires that the interior of theblocks have a cement agent poured into the cavity or cavities and thatthe cavities have one or more reinforcing rods extending from theinterior of the block into the concrete blocks that are above and below.One Example of a steel block is disclosed in U.S. Pat. No. 5,648,391,issued to Mr. Layne, on Jul. 22, 1997. The entire disclosure of thispatent is hereby incorporated herein by reference.

In view of the above, there exists a need for an embeddable mountingdevice which overcomes the above mentioned problems in the prior art.This invention addresses this need in the prior art as well as otherneeds, which will become apparent to those skilled in the art from thisdisclosure.

SUMMARY OF THE INVENTION

One object of this invention is to provide an embeddable fixturemounting device that is used to install electrical fixtures or deviceswithin a concrete block wall, a masonry wall or a pre-cast concretewall.

Another object of the present invention is to provide an embeddablemounting device that will not require additional plastering of the wallswhen the fixture or wiring device is installed.

A further object of the invention is to provide a method of permanentlyand securely mounting a fixture to a wall that access can not beaccessed without the use of security tools.

Another object of the present invention is to provide an embeddablemounting device that will assist in the installation of a structuralsupport member such as a joist.

The new steel electrical box block in accordance with the presentinvention is designed to eliminate some of the problems that have beenexperienced by the construction industry. The electrical box block ofthe present invention reduces the cost of installation and provides asteel block that is designed specifically to receive or become thein-wall electrical box. The electrical box block can be either ahalf-size block or a full size block.

In accordance with one aspect of the present invention, a steelelectrical box block is provided which includes three rectangular metalplates coupled together by four vertical spacers and two horizontalplates. The first rectangular metal plate member has a first innersurface, a first outer surface, a first length measuring between seveninches and eight inches, a first height measuring between seven andeight inches, a first depth measuring between seven inches and eightinches and a first thickness of either ten gauge steel, twelve gaugesteel, fourteen gauge steel, one-quarter inch or one-half inch. Thesecond rectangular metal plate member has a second inner surface, asecond outer surface, a second length of measurement equal to the firstlength, a second height equal to the first height, a second depth equalto the first depth and a second thickness equal to the first thickness.The third rectangular metal plate member which is a removable face platehas a third inner surface, a third outer surface, a third length ofmeasurement equal to the first length, a third height equal to the firstheight, a third depth equal to the first depth and a third thicknessequal to the first thickness. Of course, these rectangular metal platemembers can have other dimensions as need and/or desired of a particularapplication. Also, an octagonal or square hole of an appropriate size isformed in the third rectangular metal plate member to accommodate thespecific fixture that will be utilized.

The third rectangular metal plate will be further equipped with holes ofvarying sizes so that security screws can be used to set the plate. Thesteel electric fixture box has also two pair of spacer members, eachhaving two (2) one-quarter (¼″) inch radius breaks that extend to eachside of the block a length of one to two inches. One pair of spacermembers is secured between the first inner surface and the second innersurface in a manner to create at least one reinforcing rod and cementreceiving cavity between the first and second metal plate members. Thesespacer members hold the first and second metal plate members in parallelrelationship with each other. When the first and second metal platemembers simultaneously contact a planar surface, the first and secondmetal plate members are both perpendicularly oriented to the planarsurface. The first and second outer surfaces of the first and secondrectangular metal plate members are spaced apart a spacing distancemeasuring between three (3″) and five (5″) inches. The area filled bythe cement/grout mixture that is placed between adjacent blocks isfurther used to present a plurality of the concrete blocks together toform the wall. The second pair of spacer members is secured between thesecond inner surface and the third inner surface in a manner to create ahousing chamber to receive the conduit and mount the electric fixture orelectric device as required.

It is the object of this invention to provide a means for easilyconnecting low voltage lines and those above 115 volts that must be runin conduit. Also, high voltage lines (electrical power lines or thelike) and low voltage lines (speaker cables or the like) can easily beconnected by using female snap-on connectors. This inventor visualizesthat the speakers are field applied to the faceplate with a male pigtailconnector. In instances in which high voltage electrical components arerequired, it is the intent of this invention that a flexible piece ofconduit securely attached to the rigid conduit will provide a sufficientraceway for bringing the electrical wires to their final terminationpoint. The final termination point will be a UL listed electrical boxattached to the faceplate so that the appropriate electrical switches orreceptacles are placed therein. Upon the termination of the wires intothe electrical box which has been attached to the backside of the steelblock electrical fixture box faceplate, the faceplate will then beattached to the steel block electrical fixture box using security screwsand an electrical faceplate shall be attached.

These spacer members are placed in a manner to hold the second and thirdmetal plate members in parallel relationship with each other such thatwhen said second and third metal plate members simultaneously contact aplanar surface the second and third metal plate members are bothperpendicularly oriented to the planar surface, and in a manner suchthat the second and third outer surfaces are spaced apart a spacingdistance measuring between three (3″) and four and one-half (4½″)inches. Each of the spacer members are of varying heights depending uponthe reinforcing bars that may be run horizontally at both the top andbottom.

It would also be desirable to have a method for mounting an electricfixture, including electrical switches/receptacles, electrical intercomspeakers, etc., correctly sized, level and plumb permanently within aconcrete block wall that did not require degradation of the wallstructure by forming a cavity within the pre-existing concrete blockswhen it became necessary to install a fixture as identified above.

The steel electrical box block has its first and second rectangularmetal plate members sized to allow the masonry setting installation ofthe steel block within the total concrete block wall to be filled with acementing slurry mixture and the grouting of all edges. It had beenthought originally that direct contact of the steel block with theadjacent concrete blocks might reduce the potential loosening effectthat was thought to occur by the shrinking or squeezing out of thecement slurry or grouting when the blocks and mounting devices were laidand grouted in place as with a standard concrete block installation.Testing has proven that steel blocks, properly grouted, do notexperience the shrinking or loosening effect. Proper grouting,“cementing slurry” filling and properly set reinforcing rods aremandatory for the proper setting of all steel blocks. Steel blocks thatare grouted and filled properly are no more or less vulnerable to being“dug out” then normal concrete blocks are. The first and secondrectangular metal plate members create a cement receiving cavity that isaligned with the reinforcing bar and cement receiving cavities ofconventional concrete blocks and into which a vertical reinforcing barand cementing slurry is introduced during the setting (installation) ofthe device. The term “cementing slurry” is used herein to indicate anyof the cementing agents conventionally poured into the reinforcing barand cement receiving cavities of conventional concrete blocks that areutilized to add strength and greater utility to the construction. Thesteel electrical box block has its second and third rectangular metalplate members sized to form the back plate (second metal plate member)and the face plate (third metal plate member) of the electrical box.

Another aspect of the invention is a permanently and securely mountedsteel electrical box block for the housing of activated electricalfixtures. The method includes the step of installing the steelelectrical box block during the setting of the concrete block walls. Thesteel electrical box block as described above is placed into the wall ina manner so that the masonry contractor can place one reinforcing barinto the aligned reinforcing bar receiving cavity and/or horizontally inthe space above or below the cavity. Prior to the final hardening of thecement slurry, the reinforcing bar members are placed vertically intothe now filled bar receiving cavities and allowed to protrude enough toengage one or more courses of concrete blocks that will be set in thefollowing concrete block courses. The cementing slurry mixture is thenallowed to harden. After the cementing slurry mixture has hardenedsufficiently to at least hold the mounting device in place, a fixture orwiring device can be permanently fixed to the wall by using securityscrews.

In accordance with another aspect of the present invention, anembeddable mounting device is provided in the form of joist supportblock. The joist support block basically includes a pair of generallyrectangular metal members, three metal spacer members, two verticalmetal walls or members and a horizontal metal wall or member. The twovertical metal walls or members and a horizontal metal wall or memberform a U-shaped support member, which allows the structural supportmember or joist to be easily coupled to the joist support block.

These and other objects, features, aspects and advantages of the presentinvention will become apparent to those skilled in the art from thefollowing detailed description, which, taken in conjunction with theannexed drawings, discloses a preferred embodiment of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of thisoriginal disclosure:

FIG. 1 is a perspective view of an embeddable mounting device in theform of an electrical box block in accordance with one embodiment of thepresent invention;

FIG. 2 is a top plan view of the embeddable mounting device orelectrical box block illustrated in FIG. 1 in accordance with the firstembodiment of the present invention;

FIG. 3 is a front elevational view of the embeddable mounting device forblock illustrated in FIGS. 1 and 2 in accordance with the firstembodiment of the present invention;

FIG. 4 is a right side elevational view of the embeddable mountingdevice or block illustrated in FIGS. 1-3 in accordance with the firstembodiment of the present invention;

FIG. 5 is a partial perspective view of the embeddable mounting deviceor block partially mounted in a block wall in which the electrical boxis being used to mount a lighting fixture in accordance with the firstembodiment of the present invention;

FIG. 6 is a partial perspective view of the embeddable mounting deviceor block being mounted in a block wall in which the embeddable mountingdevice or block is designed for an electrical wiring device such as areceptacle;

FIG. 7 is a perspective view of an embeddable mounting device in theform of an electrical box block in accordance with another embodiment ofthe present invention;

FIG. 8 is a bottom plan view of the embeddable mounting device orelectrical box block illustrated in FIG. 7 in accordance with the secondembodiment of the present invention;

FIG. 9 is a partial perspective view of an embeddable mounting device orjoist support block in accordance with another embodiment of the presentinvention ;

FIG. 10 is a perspective view of a cover plate member for the embeddablemounting device or block illustrated in FIG. 9 in accordance with thethird embodiment of the present invention;

FIG. 11 is a top plan view of the embeddable mounting device or joistsupport block illustrated in FIG. 9 with the cover plate member mountedthereto in accordance with the third embodiment of the presentinvention;

FIG. 12 is a front elevational view of the embeddable mounting device orblock illustrated in FIG. 11 in accordance with the second embodiment ofthe present invention;

FIG. 13 a right side elevational view of the embeddable mounting deviceor block illustrated in FIGS. 11 and 12 in accordance with the secondembodiment of the present invention; and

FIG. 14 is a partial perspective view of a block with two embeddedmounting devices or joist support blocks of type illustrated in FIGS.11-13 mounted therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIG. 1, a perspective view of an embeddablemounting device or electrical box block 10 is illustrated in accordancewith one embodiment of the present invention. Mounting device or block10 basically includes three generally rectangular metal members 12, 14and 28, four metal spacer members 16, 18, 20 and 22, and two horizontalmetal members 24 and 26. Preferably, these metal members are constructedof metal plates to form a metal block, which are capable of mounting anelectrical fixture or device. As seen in FIGS. 5 and 6, the embeddablemounting device or electrical box block 10 is embedded within a blockwall 11 constructed of blocks 13 such as cinder blocks, concrete blocksor masonry blocks. The embeddable mounting device or electrical boxblock 10 is designed to be grouted just like the cinder blocks, concreteblocks or masonry blocks 13. Thus, the embeddable mounting device orelectrical box block 10 preferably has a height “A” between about seveninches and nine inches, a length “B” between about seven inches andseventeen inches and a depth or width “C” preferably between seveninches and nine inches. This size of block 10 allows the block tocompletely fill the space normally occupied by a conventional cinderblock, concrete block or masonry block. While the mounting device orelectrical box block 10 is illustrated as a half block, it will beapparent to those skilled in the art from this disclosure that themounting device or electrical box block 10 can be a full block, i.e.,the same size as the cinder blocks, concrete blocks or masonry blocks13.

It will be apparent to those skilled in the art from this disclosurethat these metal plate members 12, 14, 16, 18, 20, 22, 24, 26 and 28 canbe constructed of several plates which are fixedly secured together bysuitable means such as welding. It will also be apparent to thoseskilled in the art from this disclosure that some of these metal platemembers 12, 14, 16, 18, 20, 22, 24, 26 and 28 can be constructed from asingle plate which is bent to form two or more of the metal platemembers. For example, the first and second rectangular metal members 12and 14 can be integrally formed with metal spacer member 16 by bending ametal plate into a U-shaped member.

In the illustrated embodiment, the first and second rectangular metalplate members 12 and 14 are both preferably constructed of one-quarter(¼″) inch thick mild steel plates. However, lesser gauges of steel canbe used if applicable. The first and second rectangular metal platemembers 12 and 14 each have a height “A” of about seven and five-eighths(7⅝″) inches, a length “B” of about seven and five-eighths (7⅝″) inches.The depth “C” of block 10 is preferably about seven and five-eighths(7⅝″) inches. Similarly, third rectangular metal plate member 28 isconstructed of ten gauge mild steel plate which has a height and alength that are substantially the same as the first and second metalplate members 12 and 14. In the case of a full size block, therectangular metal plate members 12, 14 and 28 are preferably constructedwith a height “A” of about eight and five-eighths (8⅝″) inches and awidth “B” of about fifteen and five-eighths (15⅝″) inches. The depth “C”of a full size block 10 would still preferably be about seven andfive-eighths (7⅝″) inches. Of course, it will be apparent to thoseskilled in the art from this disclosure that the size of the embeddablefixture mounting device or electrical box block 10 can be other sizesdepending upon the cinder blocks, concrete blocks or masonry blocksbeing used therewith.

Referring now to FIG. 2, the first and second rectangular metal platemembers 12 and 14 are planar members, which are secured together by thefirst and second spacer members 16 and 18 so as to be spaced apredetermined distance apart from each other. The first and secondspacer members 16 and 18 hold the first and second rectangular metalplate members 12 and 14 substantially parallel to each other. A concreteor cement receiving cavity 30 is formed between the first and secondrectangular metal plate members 12 and 14 and the first and secondspacer members 16 and 18.

As seen in FIGS. 5 and 6, the cavity 30 is designed to receivereinforcing bars 32 and cement 34 therein. The first and second spacermembers 16 and 18 are preferably constructed from one-quarter (¼″) inchthick mild steel plate. The first and second spacer members 16 and 18can have the same or a smaller height than the first and secondrectangular metal plate members 12 and 14. Moreover, the height of thefirst and second spacer members 16 and 18 can vary if needed and/ordesired.

The side edges of first and second spacer members 16 and 18 are bent toform attachment flanges. These bends of spacer members 16 and 18preferably have a radius of about one-quarter (¼″) inch radius. Thesebends are located about one (1″) inch from the side edges and runparallel to the rectangular metal plate members. These bends are formedin a manner to form spacer members 16 and 18 with U-shaped crosssections. The spacer members 16 and 18 each includes a central section16 a or 18 a, a first leg section 16 b or 18 b and a second leg section16 c or 18 c respectively. The leg sections 16 a and 18 a are fixedlycoupled to the first rectangular metal plate member 12, while the legsections 16 b and 18 b are fixedly coupled to the second rectangularmetal plate member 14.

The second and third rectangular metal plate members 14 and 28 aresecured together by third and fourth spacer members or opposed walls 20and 22 to form a space therebetween for receiving either electrical box40 a or 40 b as seen in FIGS. 5 and 6. The third and fourth spacermembers 20 and 22 are preferably constructed from ten gauge mild steelplate. The third and fourth spacer members 20 and 22 preferably have thesame height as the first and second rectangular metal plate members 12and 14. Of course, the height of third and fourth spacer members 20 and22 can vary if needed and/or desired.

The side edges of third and fourth spacer members 20 and 22 are bent toform attachment flanges. These bends preferably each have a radius ofabout one-quarter (¼″) inch. The bends are located about one (1″) inchfrom the side edge and run parallel to the rectangular metal platemembers. The bends are formed in a manner to form spacer members 20 and22 with U-shaped cross sections. The spacer members 20 and 22 eachincludes a central section 20 a or 22 a, a first leg section 20 b or 22b and a second leg section 20 c or 22 c, respectively. Leg sections 20 cand 22 c of third and fourth spacer members 20 and 22 have been drilledand tapped to form a pair of mounting flanges with threaded holes 42that receive security screws 44 for securing the third rectangular metalplate member 28 thereto.

The first and second horizontal plate members 24 and 26 are fixedlysecured to the second rectangular metal plate member 14 and the thirdand fourth spacer members 20 and 22. The first and second horizontalplate members 24 and 26 extend substantially perpendicular to the secondrectangular metal plate member 14, as well as extend substantiallyperpendicular to the central sections 20 a and 22 a of the spacermembers 20 and 22. Accordingly, a rectangularly shaped box member havinga rectangular cross section is formed by the central sections 20 a and22 a (first and second opposed walls and the horizontal plate members 24and 26 (third and fourth opposed walls.

When the third rectangular plate member 28 is attached to the secondlegs 20 c and 22 c of the third and fourth spacer members 20 and 22, anelectrical enclosure is formed. This enclosure can be an electricaloutlet box by itself, or can have an electrical box 40 a or 40 b fixedlysecured therein. The third and fourth spacer members 20 and 22 can beinverted and the first and second horizontal plate members or walls 24and 26 can be made longer to increase the internal volume of theenclosure without increasing the overall size of the mounting device 10.

As best seen in FIGS. 5 and 6, the first and second horizontal platemembers 24 and 26 each have a punch-out or hole 46 or 48 for receivingan electrical conduit therethrough. Holes 46 and 48 are preferablyaligned with each other and located in the center of their respectivehorizontal plate members 24 or 26. As seen in FIGS. 2 and 3, a groundscrew 49 can be threaded into a hole in the spacer member 20. Theprecise location of the ground screw 49 is not important. Thus, theground screw 49 could be coupled to one of the horizontal plate members24 or 26, if desired.

Referring again to FIGS. 1 and 3, the third rectangular plate member 28has a centrally located cutout or opening 50, four mounting holes 52located symmetrically around the cutout or opening 50 and four mountingholes 54 located at the corners of the third rectangular plate member28. The opening 50 can be, for example, an octagonal cutout, whichmeasures three and one-half (3½″) inches by four (4″) inches. Of course,opening 50 can have other shapes as needed and/or desired. The fourmounting holes 52 are located symmetrically around the cutout or opening50 and are preferably {fraction (3/16)}″ holes for receiving screws 56therethrough to mount the fixture 58 (FIG. 5) or the wiring device 60(FIG. 6) thereto. More specifically, the screws 56 first extend throughholes in the mounting plate 59 of the fixture 58 (FIG. 5) or the faceplate 61 of the wiring device 60 (FIG. 6). Then, the screws 56 extendthrough the mounting holes 52 of the third plate member 28 where thescrews 56 are threaded into the threaded holes of the electrical box 40a or 40 b. Alternatively, mounting holes 52 can be threaded forthreadedly receiving the screws 56 to secure the electrical fixture 58or the wiring device 60 directly to the third rectangular plate member28.

The four mounting holes 54 of the third rectangular plate member 28 arepreferably {fraction (3/16)}″ holes, which are located one-half (½″)inch inward from each corner of the third rectangular plate member 28.Holes 54 threadedly receive security screws 44 therein to removablysecure the third rectangular plate member 28 to leg sections 16 c and 18c of spacer members 16 and 18.

Referring again to FIGS. 5 and 6, perspective views of partiallyconstructed concrete block walls 11 are illustrated. Block wall 11 isconstructed from a plurality of conventional blocks 13 such as cinderblocks, concrete blocks or masonry blocks. Each of the blocks 13includes a pair of cement receiving cavities 62. A mounting device 10 isshown installed between the concrete blocks 13 so that the mountingdevice 10 becomes an integral part of block wall 11.

An exemplary method of installing the embeddable mounting device intothe block wall 11 will now be described with general reference to FIGS.1-4 and particular reference to FIGS. 5 and 6. In this exemplary methodof permanently attaching and embedding the electrical box 10 into theblock wall 1 1, the method includes the step of installing at least onemounting device or steel block 10, as described above, into the blockwall 11 in place of one of the blocks 13 during construction of theblock wall 11. Installation of mounting device or steel block 10 is asfollows. First, the cinder, concrete or masonry blocks 13 are laid downto begin construction of the concrete wall 11. Next, the mounting device10 is placed unto one or more of the cinder, concrete or masonry blocks13 of the wall 11 in a desired location. One of the reinforcing bars 32is received in the cavity 30 of the mounting device or steel block 10.The cavity 30 is at least partially aligned with one of the cementreceiving cavities 62 of one of the cinder, concrete or masonry blocks13. With the vertical reinforcing bars 32 in place, a cementing slurrymixture is then poured into the cavities 30 and 62 in a manner such thatthe vertical reinforcing bars 32 and a quantity of the cementing slurrymixture fill the cement receiving cavity 30 of mounting device or steelblock 10 and the cement receiving cavities 62 of cinder, concrete ormasonry blocks 13.

The cementing slurry mixture is then allowed to harden while the wall 11is fully constructed. Once wall 11 is fully constructed, an electricaldevice, such as a lighting fixture 58 or wiring device 60 can be affixedto the third rectangular metal plate member 28.

Second Embodiment

Referring now to FIGS. 7 and 8, a perspective view of an embeddablemounting device or electrical box block 10′ is illustrated in accordancewith another embodiment of the present invention. The mounting device orsteel block 10′ is basically identical to the steel electrical block 10,as discussed above, except that the mounting device or steel block 10′is a full size block which forms a pair of electrical enclosures orboxes. In view of the similarities between the steel block 10′ and thesteel block 10, the steel block 10′ will not be discussed or illustratedin detail herein. Accordingly, in the following description of thesecond embodiment of the present invention, parts and portions which arethe same as or similar to those of the first embodiment will be giventhe same reference numbers but with a prime (') added to the referencenumbers.

Basically, the mounting device or steel block 10′ includes threegenerally rectangular metal members 12′, 14′ and 28′, six metal spacermembers 16′, 17′, 18′, 20′, 21′ and 22′, and two horizontal metalmembers 24′ and 26′. Preferably, these metal members are constructed ofmetal plates to form a metal block, which are capable of mounting anelectrical fixture or device. The embeddable mounting device orelectrical box block 10′ is designed to be grouted just like the steelblock 10 and the cinder, concrete or masonry blocks 13, which arediscussed above. This size of block 10′ allows the block to completelyfill the space normally occupied by a conventional full size cinderblock, concrete block or masonry block. Thus, the embeddable mountingdevice or electrical box block 10′ preferably has a height “A” betweenabout seven inches and nine inches, a length “B” between about fifteeninches and seventeen inches and a depth or width “C” preferably betweenseven inches and nine inches.

Third Embodiment

Referring now to FIGS. 9-14, an embeddable mounting device or joistsupport block 110 is illustrated in accordance with another embodimentof the present invention. Mounting device or steel block 110 of thisembodiment is especially designed for supporting a joist or supportmember 115 as seen in FIG. 14. Mounting device or steel block 110basically includes a pair of generally rectangular metal members 112 and114, three metal spacer members 116, 118 and 120, two vertical metalsupport walls or members 122 and 124 and a horizontal metal support wallor member 126. Preferably, these metal members are constructed of metalplates to form a metal block, which are capable of supporting the joistor support member 115. As seen in FIG. 14, the embeddable mountingdevice or joist support block 110 is embedded within a block wall 111,which is constructed of concrete, cinder or masonry blocks 113.

While the mounting device or joist support block 110 is illustrated as afull block, it will be apparent to those skilled in the art from thisdisclosure that the mounting device or joist support block 110 can be ahalf block, i.e., the same size as a standard half concrete, cinder ormasonry block. The embeddable mounting device or joist support block 110is designed to be grouted just like the concrete, cinder or masonryblocks 113 or the steel electrical box block 10, discussed above. Thus,the embeddable mounting device or joist support block 110 preferably hasa height “A” between about seven inches and nine inches, a length “B”between about fifteen inches and seventeen inches and a depth “C”preferably between seven inches and nine inches. This size of block 10allows the block to completely fill the space normally occupied by aconventional concrete, cinder or masonry block.

It will be apparent to those skilled in the art from this disclosurethat these metal plate members 112, 114, 116, 118, 120, 122, 124 and 126can be constructed of several plates which are fixedly secured togetherby suitable means such as welding. It will also be apparent to thoseskilled in the art from this disclosure that some of these metal platemembers 112, 114, 116, 118, 120, 122, 124 and 126 can be constructedformed of a single plate which is bent to form two or more of the metalplate members. For example, the first and second rectangular metalmembers 112 and 114 can be integrally formed with metal spacer member116 by bending a metal plate into a U-shaped member.

In the illustrated embodiment, the first and second rectangular metalplate members 112 and 114 are both preferably constructed of one-quarter(¼″) inch thick mild steel plates. Of course, the first and secondrectangular metal plate members 112 and 114 can be fabricated of alesser gauge metal plate if needed and/or desired. The first and secondrectangular metal plate members 112 and 114 preferably are dimensionedto have a height “A” of approximately seven and five-eighths (7⅝″)inches and a length “B” of approximately fifteen and five-eighths (15⅝″)inches. The depth “C” of block 110 is preferably approximately seven andfive-eighths (7⅝″). Of course, it will be apparent to those skilled inthe art from this disclosure that the size of the embeddable mountingdevice or joist support block 110 can be other sizes depending upon theother blocks being used therewith.

As best seen in FIG. 9, an L-shaped support bracket 128 is fixedlysecured to the outer surface of the second rectangular metal platemember 114 by suitable means. Bracket 128 is located at the upper edgeof the second rectangular metal plate member 114 such that the uppersurface is substantially aligned with the upper edge of the secondrectangular metal plate member 114. The bracket 128 is constructed of ahard rigid material such as a steel angle member. The dimensions of eachplanar section 128 a and 128 b of bracket 128 are preferablyapproximately three (3″) inches in length and two (2″) inches wide.Preferably, the thickness of the material used to create bracket 128 isabout one-quarter (¼″) inch thick. Bracket 128 is located mid-waybetween the vertical edges of the second rectangular metal plate member114 so that the end of a concrete, cinder or masonry block 113 will besupported thereon.

As can best be seen in FIG. 10, an optional cover plate member 130 isprovided for covering the opening of the U-shaped support member formedby plate members or walls 122, 124 and 126. Cover plate member 130 ispreferably constructed from a flat planar metal material such asfourteen gauge steel plate. The cover plate member 30 is preferablydimensioned to have a length of approximately fifteen and five-eighths(15⅝″) inches, and a width of approximately four and five-eighths (4⅝″)inches. On the bottom side of the cover plate member 130 are four clips132, 134, 136 and 138. Clips 132 and 136 are designed to engage secondrectangular metal plate member 114, while clips 134 and 138 are designedto engage the side support walls or members 122 and 124, respectively.Clips 132, 134, 136 and 138 are preferably L-shaped members which arefixedly secured to the bottom surface of the cover plate member 130. Thebottom surface of cover plate member 130 also preferably rests on top ofthe bracket 128.

Referring now to FIG. 11, the first and second rectangular metal platemembers 112 and 114 are secured together by the first, second and thirdspacer members 116, 118 and 120 so as to be spaced a predetermineddistance apart from each other. The first, second and third spacermembers 116, 118 and 120 hold the first and second rectangular metalplate members 112 and 114 substantially parallel to each other. Twoconcrete receiving cavities 131 are formed between the first and secondrectangular metal plate members 112 and 114 and the first, second andthird spacer members 116, 118 and 120.

As seen in FIG. 14, the cavities 131 are designed to be able to receiveone of the reinforcing bars 133 and cement 135 therein. The first,second and third spacer members 116, 118 and 120 are preferablyconstructed from one-quarter (¼″) inch thick steel plate. The first,second and third spacer members 116, 118 and 120 can have the same or asmaller height than the first and second rectangular metal plate members112 and 114. Moreover, the heights of the first, second and third spacermembers 116, 118 and 120 can vary if needed and/or desired.

The side edges of first, second and third spacer members 116, 118 and120 are bent to form attachment flanges. The bends preferably have aradius of about one-quarter (¼′) inch radius, which is located about one(1′) inch from the side edge and runs parallel to the rectangular metalplate members 112 and 114. These bends are formed in a manner to formspacer members 116, 118 and 120 with U-shaped cross sections. The spacermembers 116, 118 and 120 each includes a central section 116 a, 118 a or120 a, a first leg section 116 b, 118 b or 120 b and a second legsection 116 c, 118 c or 120 c, respectively. As seen in FIG. 11, the legsections 116 a, 118 a or 120 a are fixedly coupled to the firstrectangular metal plate member 112, while the leg sections 116 b, 118 band 120 b are fixedly coupled to the second rectangular metal platemember 114.

The metal plate members or support walls 122, 124 and 126 are securedtogether by the second rectangular plate member 114 to form a U-shapedmember with a space therebetween for receiving the joist or structuralsupport member 115 as seen in FIG. 14. The support walls or members 122,124 and 126 are preferably constructed from ten gauge steel plate. Theside support walls or members 122 and 124 preferably have the sameheight as the first and second rectangular metal plate members 112 and114. Of course, the height of side support walls or members 122 and 124can be slightly smaller if needed and/or desired.

The horizontal plate member or lower support wall 126 is fixedly securedto the second rectangular metal plate member 114 in a conventionalmanner. The horizontal plate member or lower support wall 126 has alength “A” which is substantially equal to the length “A” of the firstand second rectangular plate members 112 and 114. The horizontal platemember or lower support wall 126 extends substantially perpendicular tothe second rectangular metal plate member 114, as well as extendssubstantially perpendicular to the side support walls 122 and 124. Thelower support wall 126 rests on the cement overlying the concrete,cinder or masonry blocks 113 that supports the joist support block 110.The structural support member 115 rests on the lower support wall 126.

Referring to FIGS. 14, a perspective view of a partially constructedconcrete block wall 111 is illustrated. Block wall 111 is constructedfrom a plurality of conventional concrete, cinder or masonry blocks 113.Each of the concrete, cinder or masonry blocks 113 includes a pair ofcement receiving cavities 162. A pair of mounting devices or steelblocks 110 is shown installed between concrete, cinder or masonry blocks113.

An exemplary method of installing the embeddable mounting devices orsteel blocks 110 into the block wall 111 will now be described withgeneral reference to FIGS. 9-13 and particular reference to FIGS. 14. Inthe exemplary method of permanently attaching and embedding the joistsupport block 110 into the block wall 111, the method includes the stepof installing at least one mounting device or steel block 110, asdescribed above, into the block wall 111 in place of one of the blocks113 during construction of the block wall. Installation of mountingdevice or block 110 is as follows. First, concrete, cinder or masonryblocks 113 are laid down to begin construction of the concrete wall 111.Next, the mounting device or steel block 110 is placed unto one or moreof the blocks 113 of the wall 111 in a desired location. One of thereinforcing bars 133 is received in the cavity 131 of the mountingdevice or steel block 110. The cavities 131 are at least partiallyaligned with one of the cement receiving cavities 162 of one of theblocks 113. With the vertical reinforcing bars 133 in place, a cementingslurry mixture is then poured into the cavities 131 and 162 in a mannersuch that the vertical reinforcing bars 133 and a quantity of thecementing slurry mixture fill the cement receiving cavities 131 ofmounting device or steel block 110 and the cement receiving cavities 162of blocks 113. Before placing cover plate member 130 on the mountingdevice or steel block 110, the joist or support member 115 is maneuveredso that its end rests on the lower support wall 126. Now the optionalcover plate member 130 can be installed on the mounting device or steelblock 110 if needed and/or desired. The purpose of the cover platemember 130 is to limit contaminants, i.e., the cementing slurry mixtureor other fill, from falling into the U-shaped support formed by thesupport walls 122, 124, and 126. The cementing slurry mixture is thenallowed to harden while the block wall 111 is fully constructed.

While three embodiments have been chosen to illustrate the presentinvention, it will be apparent to those skilled in the art from thisdisclosure that various changes and modifications can be made hereinwithout departing from the scope of the invention as defined in theappended claims. Furthermore, the foregoing description of theembodiments according to the present invention are provided forillustration only, and not for the purpose of limiting the invention asdefined by the appended claims and their equivalents. In other words, itis to be understood that the details herein are to be interpreted asillustrative and not in a limiting sense, and that many varying anddifferent embodiments may be made within the scope of the inventiveconcept(s) taught herein.

What is claimed is:
 1. An embeddable mounting device for embedding in ablock wall and supporting a structural support member, said embeddablemounting device comprising: a first rectangularly shaped metal memberhaving a first outer surface, a first inner surface, a first length, afirst height and a first predetermined thickness between said firstouter surface and said first inner surface; a second rectangularlyshaped metal member having a second outer surface, a second innersurface, a second length, a second height and a second predeterminedthickness between said second outer surface and said second innersurface, said second length and said second height of said secondrectangular metal member being substantially equal to said first lengthand said first height, respectively; a pair of spacer members coupledbetween said first rectangularly shaped metal member and said secondrectangularly shaped metal member to form a block with a hollow interiorin which said first rectangularly shaped metal member and said secondrectangularly shaped metal member are arranged substantially parallel toeach other and said spacer members extend between said first and secondrectangularly shaped metal members; and a U-shaped support memberextending from said second member, said support member being constructedof metal and having a lower wall with first and second support surfacesand a pair of opposed side walls with upper free edges, said lower walland said pair of opposed side walls extending substantiallyperpendicularly from said second member, said U-shaped support memberbeing open for receiving a structural support member.
 2. An embeddablemounting device according to claim 1, further comprising a bracketfixedly coupled to said second member adjacent an upper edge of saidsecond member.
 3. An embeddable mounting device according to claim 2,wherein said bracket is an L-shaped member.
 4. An embeddable mountingdevice according to claim 2, wherein said bracket has an outer surface,which is substantially aligned with an edge of said first member.
 5. Anembeddable mounting device according to claim 2, further comprising aremovable cover overlying said bracket.
 6. An embeddable mounting deviceaccording to claim 2, wherein said bracket is located approximatelymidway between said side walls.
 7. An embeddable mounting deviceaccording to claim 1, wherein said lower wall has a length, which issubstantially equal to said length of said first member.
 8. Anembeddable mounting device according to claim 7, wherein said side wallshave heights, which are substantially equal to said height of said firstmember.
 9. An embeddable mounting device according to claim 1, whereinan additional spacer is coupled between said first and second members.10. An embeddable mounting device according to claim 1, furthercomprising a removable cover overlying said upper free edges of saidside walls.
 11. A method of supporting a structural support member in aconcrete block wall, comprising the steps of: a) providing at least oneembeddable mounting device comprising: a first rectangularly shapedmetal member having a first outer surface, a first inner surface, afirst length, a first height and a first predetermined thickness betweensaid first outer surface and said first inner surface; a secondrectangularly shaped metal member having a second outer surface, asecond inner surface, a second length, a second height and a secondpredetermined thickness between said second outer surface and saidsecond inner surface, said second length and said second height of saidsecond rectangular metal member being substantially equal to said firstlength and said first height, respectively; a pair of spacer memberscoupled between said first rectangularly shaped metal member and saidsecond rectangularly shaped metal member to form a block with a hollowinterior in which said first rectangularly shaped metal member and saidsecond rectangularly shaped metal member are arranged substantiallyparallel to each other and said spacer members extend between said firstand second rectangularly shaped metal members; and a U-shaped supportmember extending from said second member, said support member beingconstructed of metal and having a lower wall with first and secondsupport surfaces and a pair of opposed side walls with upper free edges,said lower wall and said pair of opposed side walls extendingsubstantially perpendicularly from said second member, said U-shapedsupport member being open for receiving structural support member; andb) installing said mounting device into the concrete block wall in placeof a conventional concrete block, said mounting device being placed intothe concrete block wall in a manner such that said hollow interior ofsaid mounting device is aligned with at least one cavity of a concreteblock of the concrete block wall; and c) pouring a cementing slurry intosaid cavity of the concrete block and said hollow interior of saidmounting device.
 12. The method of claim 11, wherein inserting at leastone vertical reinforcing bar through said cavity of said concrete blockand said hollow interior of said mounting block.